Hey thanks for the replies.
Maru, sure here's an example scene attached. It becomes more prominent on dark materials and metals than white. So, I made the material dark, with white you can hardly see the problem. And its not always a problems except when you want to exaggerate edges.
But on these models I cannot make the edge disappear from the flat surface and the cylinder, no matter how I change directionality (you can make it disappear on the cylinder but then the hard edge AO almost disappear too). Also it's impossible to have a thin edge line with completely opaque/hard color with Corona AO, its almost always a slight blend between the two colors on the edge (even with a color correction layer on the AO)
sprayer, thanks! Yeah round edges works as long as there's no chamfer or soft edge, too bad, if it had worked with multiple angles, not only hard edge, it would have been a perfect Curvature map. I can't think that could be a hard material to make based on that (corona team?) - just add a treshold/max min curve